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Method and arrangement for building metallic objects by solid freeform fabrication

a technology of freeform fabrication and solid structure, applied in the direction of chemical vapor deposition coating, process and machine control, program control, etc., can solve the problem of limiting the application of ti to the effect of reducing the sensitivity of the ti layer, affecting the accuracy of the welding technique, and affecting the ti layer

Active Publication Date: 2016-11-01
NORSK TITANIUM
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

This approach enables rapid and efficient production of titanium and titanium alloy objects with enhanced mechanical properties and reduced material waste, achieving deposition rates up to 10 kg / hour while maintaining dimensional accuracy and minimizing oxidation.

Problems solved by technology

The accuracy of the welding technique is usually too coarse to allow directly forming the object with acceptable dimensions.
The electron beam technology has a disadvantage of being dependent upon a high vacuum of 10−1 Pa or less in the deposition chamber.
Gas metal arc techniques have several disadvantages that severely limit their application to depositing Ti.
These drawbacks include instabilities in metal transfer, excessive spatter, and poor control of the deposited layer shape, and high heat input that causes distortion of thin sections during deposition.
Also, an increase in productivity is not possible because of wandering of the cathode spot that occurs during deposition.

Method used

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  • Method and arrangement for building metallic objects by solid freeform fabrication
  • Method and arrangement for building metallic objects by solid freeform fabrication
  • Method and arrangement for building metallic objects by solid freeform fabrication

Examples

Experimental program
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first example embodiment

[0049]The first example embodiment of the arrangement according to second aspect of the invention is shown schematically in FIG. 3. The figure shows a holding substrate 1 made of a Ti-6Al-4V alloy shaped as a rectangular cuboid, onto which a three-dimensional object made of the same Ti-6Al-4V alloy is to be formed by solid freeform fabrication. The figure displays the initial part of the deposition process where the first welding stripe 2 of Ti-6Al-4V alloy is being deposited.

[0050]A wire 3 made of the Ti-6Al-4V alloy is continuously being supplied by a wire feeder 4 which positions the wire 3 such that its distal end is located above the molten pool 5 at the deposition area on the holding substrate 1. The wire 3 is given a velocity indicated by the upper arrow on the Figure which corresponds to the heating and melting rate of the distal end such that droplets 6 of molten wire are continuously being supplied to the molten pool 5.

[0051]A first plasma transferred arc 7 is formed by a ...

second example embodiment

[0053]The second example embodiment of the invention is the first example embodiment given above including additional means for forming thermal pulses in the molten pool 5.

[0054]The means for forming thermal pulses is a DC power source 15 which is electrically connected to the second PTA-torch 12 such that the electrode 14 becomes the cathode and the holding substrate 1 becomes the anode. In addition, there are means 16 for pulsing the power delivered by DC power source 15 such that the arc 11 will in addition to heat and melt the wire 3, enter into the molten pool 5 with the same frequency as the pulsed power supply and thus deliver a pulsating heat flux to the molten pool. The means 16 may is regulated by the control system and provides a pulsing arc discharge into the molten pool with a frequency of 1 kHz.

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Abstract

A method and arrangement for manufacturing objects by solid freeform fabrication, especially titanium and titanium alloy objects, wherein the deposition rate is increased by supplying the metallic feed material in the form of a wire and employing two gas transferred arcs, one plasma transferred arc for heating the deposition area on the base material and one plasma transferred arc for heating and melting the feed wire.

Description

[0001]This invention relates to a method and arrangement for manufacturing objects by solid freeform fabrication, especially titanium and titanium alloy objects.BACKGROUND[0002]Structured metal parts made of titanium or titanium alloys are conventionally made by casting, forging or machining from a billet. These techniques have a disadvantage of high material use of the expensive titanium metal and large lead times in the fabrication.[0003]Fully dense physical objects may be made by a manufacturing technology known as rapid prototyping, rapid manufacturing, layered manufacturing or additive fabrication. This technique employs computer aided design software (CAD) to first construct a virtual model of the object which is to be made, and then transform the virtual model into thin parallel slices or layers, usually horizontally oriented. The physical object may then be made by laying down successive layers of raw material in the form of liquid paste, powder or sheet material resembling ...

Claims

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Application Information

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Patent Type & Authority Patents(United States)
IPC IPC(8): C23C16/513C23C16/52B23K10/02B22F3/10B23K10/00B23K9/04B33Y50/00B33Y30/00B33Y10/00B22F3/105
CPCB33Y50/00C23C16/513C23C16/52B22F3/105B22F3/1055B23K9/042B23K10/027B33Y10/00B33Y30/00Y02P10/295B23K2103/14C22C14/00Y02P10/25B22F2998/10B22F2999/00B23K10/006B23K15/0026B23K15/0033B23K15/0086B23K15/10B23K26/0608B23K26/342B23K26/348B23K26/60B23K26/702B29C64/153B33Y50/02G05B19/4099G05B2219/35134G05B2219/45135B22F12/33B22F10/362B22F10/32B22F12/13B22F12/47B22F12/48B22F10/25B22F10/22B22F12/17B22F12/43B22F10/80Y02P90/02B33Y40/10B33Y40/00B22F3/115B22F12/70B22F2201/20B22F12/41B22F2202/06B22F2202/13B23K9/1675B23K9/04B23K10/02B23K26/34B23K9/133B23K28/02B23K9/044B23K9/08B23K9/09B23K9/1006B23K9/125B23K9/167B23K9/173B23K9/23
Inventor STEMPFER, FERDINAND
Owner NORSK TITANIUM
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